DIY Exhaust Mod – Gain of 10+ HP!!! - 986 Forum - The Community for Porsche Boxster & Cayman Owners

clb0099 · 03-03-2009, 11:58 AM

******************** i like this idea.. now for my question i have the oval shaped exhaust tip.. does that just come right off ? like is it held on with a screw.. as i have not been underneath the car to know and it is also 12 degrees out with snow on the ground so not sure i am going to venture going under the car right now...

tommy986 · 03-03-2009, 12:25 PM

I think this exhaust tip configuration varies by year. Beside the obvious single vs. dual. Mine is a 2000 S, the inner tip extensions appear to be welded to the muffler and the outer polished tip is screwed in AND tack welded. So to do this mod i need a really long drill bit and it would also be hard to get the correct angle to drill into the side.

crios · 03-03-2009, 01:36 PM

That's correct. I think the tips were removable starting in 02, so anything prior is welded on and you'll need an extra long drill bit.

All mufflers still had the two pipes exiting, so two holes on each side will still need to be completed.

23109VC · 03-03-2009, 03:23 PM

we need to get someone with a 2.7 who has the "pedro" mod to do some side by side sound comparisons..

I wonder how much louder the pedro mod would be.... your mod seems to be almost the same thing... instead of adding plumbing to the outside - to route exhaust gas around the outside of the muffler, you are instead, letting it just bypass many of the internal chambers - and get out much faster - which is essentially the same thing....

i have a 2.7 2000 - and from listening to your youtube clips - the sound is a LOT different than just bone stock. it sounds louder and throatier. I like it! and it's FREE!!!! i wonder if you can "undo" it if you got sick of it???

what you need to do is find a way to put a "plug" or a bung on that hole - so when you take the wifey with you - you can just "plug" it...and make it sound like stock.. kinda like a cheapo bypass valve... open it for most of the time, and if/when you need to be super quiet...you plug it up.

i wish you lived closer to me, I want to hear it.

hey, in that video when you rolled by i got a nice shot of your yellow calipers. I like 'em!

clb0099 · 03-03-2009, 04:24 PM

So i have to get the tip removed and drill the holes ..then have the tip welded back ..Or is the any way i can do the holes without removing the tip?

sd_boxster · 03-03-2009, 07:04 PM

Started this last night, finished up this evening on my '03 non-S boxster.

The oval tip comes off by removing one 13mm bolt.

I used a 7/8" tapered bit, so the holes I wound up with are quite large - 7/8" by about 1.25 or 1.5" because of the angle at which I drilled.

I have not had a chance to open the throttle up properly - rolling on my spare right now, as I picked up a nail on the way to work today - but once I get a proper tire on, we'll see how it sounds. It currently reminds me of the Injen catback I had on my Tiburon, which I loved dearly.

The best part about this 'mod': if you hate it, pick up a used Boxster muffler for $50.

clb0099 · 03-03-2009, 07:39 PM

are you sure that is true about the oval tip as my car is a '97 and i am getting from alot of people that it is welded on and not screwed on.. and i have looked at pictures of mufflers from different yrs and some have the bolt and some looked welded on

crios · 03-03-2009, 07:48 PM

Yours are welded on, you need to buy a long drill bit, but you should be able to do without taking anything off.

http://beta.sears.com/shc/s/p_10153_12605_00966164000P?vName=Tools&keyword=1/2+Drill+Bit

Quote:

Originally Posted by clb0099

are you sure that is true about the oval tip as my car is a '97 and i am getting from alot of people that it is welded on and not screwed on.. and i have looked at pictures of mufflers from different yrs and some have the bolt and some looked welded on

crios · 03-03-2009, 07:58 PM

1.5 inches, wow! You have to post some clips!!!! How does it sound just reving it in park?

Quote:

Originally Posted by sd_boxster

Started this last night, finished up this evening on my '03 non-S boxster.

The oval tip comes off by removing one 13mm bolt.

I used a 7/8" tapered bit, so the holes I wound up with are quite large - 7/8" by about 1.25 or 1.5" because of the angle at which I drilled.

I have not had a chance to open the throttle up properly - rolling on my spare right now, as I picked up a nail on the way to work today - but once I get a proper tire on, we'll see how it sounds. It currently reminds me of the Injen catback I had on my Tiburon, which I loved dearly.

The best part about this 'mod': if you hate it, pick up a used Boxster muffler for $50.

sd_boxster · 03-04-2009, 10:02 PM

Video clip, as requested.

There is definitely a difference. My tires are once again holding air, so I went for a drive. There is some resonance at ~2900RPM, but it is not 'drone', and it's only noticeable for a range of about 100 RPM either side of 2900. Most noticeable difference is at low RPM - just sounds a little meaner.

I like it. I paid $600 or so for an Injen exhaust that didn't sound appreciably better than this.

The drill bit cost me less than 30 bucks. Not bad, considering how many people I've seen drop a thousand dollars on an exhaust they wound up hating.

davey · 10-18-2010, 02:09 AM

On the early welded single exit boxes could you not just drill one big hole between the two outlets with a tank cutter? It would have exactly the same affect.

tamarsha · 10-18-2010, 02:22 AM

Quote:

Originally Posted by davey

On the early welded single exit boxes could you not just drill one big hole between the two outlets with a tank cutter? It would have exactly the same affect.

Sounds logical to me. The whole point is to tap into that center chamber.